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  • 专利说明
  • 权利要求
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    • 专利摘要:
    TRAINING OF LAMINATED TOUCH HOLDERS. The present invention relates to a laminated touch fastener that is made in a continuous process on a mold roll (130). A flowable resin is pressed against the mold roll in limited areas for forming projections (104) extending from resin layers (106) which are laminated to a flexible substrate (102) while being carried on the mold roll. In one example, a continuous channel (155) around the mold roll is positioned so that the resin at least partially fills the channel, as the layers are formed, thereby forming an elevated portion (120) in the channel where the resin layer is thicker than at a point between the projections and the raised portion. In another example, the grooves (702) on the mold roll receive ribs (700) from a pressure applicator during the formation of the layers, the ribs blocking a lateral flow of the resin to form a desired edge profile.
    公开号:BR112014025963B1
    申请号:R112014025963-1
    申请日:2013-04-10
    公开日:2021-02-09
    发明作者:Isaac Soler Medina；James T. Grady
    申请人:Velcro BVBA；
    IPC主号:
    专利说明:

    TECHNICAL FIELD
    [001] The present invention relates to a method of manufacturing laminated touch fasteners and products produced in this way. BACKGROUND
    [002] Cheap touch fasteners, such as mechanical hook and loop fasteners, are finding widespread use in a variety of applications, including disposable clothing and diapers. For some applications, a particularly cost-effective method of producing these fasteners is what we call mold lamination - where resin is applied to a substantially carrier and is simultaneously bonded or laminated directly to the substrate, while an array of projections in miniature is molded from resin. An early example of mold lamination was taught by Kennedy et al. in U.S. Patent No. 5,260,015. Later, it was determined that the resin could be applied to the substrate in discrete streaks or islands, leaving at least a portion of the substrate surface exposed, rather than covering the entire surface. See, for example, U.S. Patent Nos. 6,205,623 and 7,048,818. Due to the fact that typical resin viscosities and projection sizes are useful for many touch fastening applications, and line speeds required for cost-effective production, the required lamination / molding pressure is often quite high.
    [003] Leaving part of the substrate exposed, however, necessarily means the formation of an edge of the resin on the surface. In some cases, the edges formed were considered rough to the touch or visually unattractive.
    [004] Improvements are sought in the formation of partially covered fastener laminates, and in products produced in this way. SUMMARY
    [005] Some aspects of the invention involve the perception that, in at least some examples, an undesirable roughness or visual objections may be the result of a non-uniform lateral flow in the pass and / or a substrate penetration by the resin at the resin edges, an effect exacerbated by narrower resin areas and high pressures required to form projections.
    [006] One aspect of the invention features a method of manufacturing a laminated touch fastener, the method including introducing flowable resin into a limited region of an outer surface of a rotating mold roll defining an arrangement of cavities extending inwardly from an external surface of the mold roll, and the application of pressure to the resin to fill the cavities in the resin and the formation of a layer of the applied resin interconnecting projections molded in the cavities. The resin layer is laminated to a flexible substrate while the resin layer is carried on the mold roll (the substrate being wider than that of the resin layer), thereby forming a laterally delimited resin layer from which the molded projections extend, the bounded layer laminated to the substrate and having at least one layer edge adjacent to an exposed region of the substrate, and the layer having a selvedge region devoid of the molded projections and defined between the projections and the layer edge . The mold roll defines a continuous channel that extends around the mold roll and positioned so that the resin at least partially fills the channel, thereby forming in the channel a raised portion of the selvedge region in which the resin layer is greater thickness than at a point between the arrangement and the raised portion.
    [007] In some cases, pressure is applied in a pass between the mold roller and a pressure roller turning in reverse. In some other cases, pressure is applied to a space between the mold roll and a non-rotating extrusion nozzle.
    [008] In some examples, the layer edge is formed in the channel. In some cases, the layer edge is formed by a resin that extends laterally beyond the channel.
    [009] The layer edge is formed, in some embodiments, against an axially distal wall that defines the channel.
    [0010] The channel can be defined between straight parallel walls, for example. In another arrangement, the channel is defined between spaced walls that follow a serpentine path, so that the channel follows a serpentine path around the mold roll.
    [0011] In many cases, the resin fills the channel, so that the resin layer is shaped to have a shape of the channel.
    [0012] Preferably, the channel has a depth, measured in a radial direction of the mold roll from the outer surface of the mold roll adjacent to the channel, which is between about 20 and 35 percent of a channel width , measured along a geometric axis of rotation of the mold roll.
    [0013] In some examples, the channel is of a constant cross-sectional area around the mold roll.
    [0014] For some applications, the mold roll cavities closest to the channel are spaced from an edge close to the channel at a distance less than 0.8 times the width of the channel, measured along a geometric axis of rotation of the mold roll.
    [0015] The substrate can be porous, with the flowable resin pressed into pores of the substrate, while the resin is carried on the mold roll. In some cases, the substrate surface is fibrous, and the pores are formed as spaces between substrate fibers. For some applications, the substrate surface is of a topography that ripples across the surface, the edge of the layer crossing ripples of the surface. A topography like this can be characterized by elevated areas bounded by connected areas, for example. The resin can be pressed into the pores of the substrate under the pressure applied to fill the cavities.
    [0016] In some arrangements, the resin layer is of a thickness in the elevated portion that is between about two and four times a thickness of the layer at a point between the arrangement and the elevated portion.
    [0017] In some examples, the channel has a bottom with a beveled edge. In some other cases, the channel has a bottom with a rounded edge. Preferably, the channel has a depth that is less than a depth of the cavities.
    [0018] In some embodiments, the mold roll defines grooves immediately out of the channels and forming an external side of each channel, and the ribs are arranged in the cavities during the application of pressure and prevent a lateral flow of the flowable resin. In some cases, the method also includes trimming the grooves after applying pressure and before lamination to the flexible substrate.
    [0019] In some cases, the method also includes, after applying pressure and before lamination to the flexible substrate, the application of heat to an exposed surface of the resin layer, while the resin layer is carried on the mold roll.
    [0020] Another aspect of the invention features a touch fastener product having a flexible sheet-shaped substrate having a wide surface, a layer of resin directly laminated to the wide surface, and an array of discrete fastener projections extending from of the resin layer. The resin layer covers only a portion of the wide surface and defines a layer edge adjacent to an exposed region of the wide surface, and the resin layer is of greater thickness at the layer edge than at a point between the arrangement and the layer border.
    [0021] In some examples, the layer edge characterizes a rib, and the layer defines an area of selvedge that extends from the fastener projection arrangement to the rib, the area of the selvedge being less than thick. thickness of the resin layer on the rib. The rib is preferably shorter than the fastening elements. In some cases, the rib has a rounded outer edge. For some applications, the rib has a height, measured from the resin layer in the selvedge area, which is between about 20 and 35 percent of a rib width.
    [0022] In some examples, the substrate is longitudinally continuous and the resin layer forms a discrete band of resin running along a length of the substrate.
    [0023] In some cases, the resin layer covers only a delimited area of the wide substrate surface and is surrounded by the exposed region of the wide surface. The layer edge features a rib that extends around a periphery of the resin layer.
    [0024] Another aspect of the invention features a method of manufacturing a laminated touch fastener, the method including introducing a flowable resin into a limited circumferential band on an outer surface of a rotating mold roll defining an arrangement of cavities if extending inwardly from an external surface of the mold roll on the web, and defining grooves on either side of the circumferential web. The mold roll is positioned in cooperation with a pressure applicator, with the well bore ribs of the pressure applicator positioned in the grooves of the rotating mold roll to delimit the circumferential band laterally. With the ribs positioned in the groove, pressure is applied to the resin to fill the cavities with resin and to form a layer of the applied resin interconnecting molded projections in the cavities and extending through the circumferential band between the ribs. The resin layer is carried on the mold roll to a position in the rotation of the mold roll where the grooves are free from the ribs, and then the resin layer is laminated to a flexible substrate while the resin layer is carried on the mold roll. The substrate is wider in width than the resin layer, and a laterally bounded resin layer is formed, from which the molded projections extend, the bounded layer laminated to the substrate and having at least one layer edge adjacent to a layer. exposed region of the substrate.
    [0025] In some examples, the method also includes the filleting of the grooves after applying pressure and before lamination to the flexible substrate.
    [0026] Some examples also characterize, after applying pressure and before lamination to the flexible substrate, the application of heat to an exposed surface of the resin layer, while the resin layer is carried on the mold roll.
    [0027] Several implementations of the inventive concepts presented here can be useful in allowing the formation of visually and tactile plating laminates, even when forming projections under very high pass pressures very close to resin edges. Dimensional variability in widths of fixing streaks or deposits can also be reduced.
    [0028] Details of one or more embodiments of the invention are set out in the associated drawings and in the description below. Other features, objectives and advantages of the invention will be evident from the description and drawings and from the claims. DESCRIPTION OF DRAWINGS
    [0029] Figure 1 is a partial end view of a touch fastener laminate.
    [0030] Figure 2 is a side view of the touch fastener in figure 1.
    [0031] Figure 3 is a partial top view of the touch fastener in Figure 1, showing one of multiple strips of resin on a substrate surface.
    [0032] Figure 4 is a partial top view of a second touch fastener that has resin islands on a substrate surface.
    [0033] Figure 5 is a cross-sectional view of figure 4, taken along line 5-5.
    [0034] Figure 6 is an enlarged cross-sectional view of the edge of the resin island shown in Figure 5.
    [0035] Figure 7 shows a first device and a method of manufacturing a touch fastener.
    [0036] Figure 8 is a cross-sectional view of figure 7, taken along line 8-8.
    [0037] Figure 9 is a partial perspective view of the face of the extruder of figure 7.
    [0038] Figure 10 shows a second device and a method of manufacturing a touch fastener.
    [0039] Figure 11 is a cross-sectional view of figure 10, taken along line 11-11.
    [0040] Figure 12 is an enlarged perspective view of an edge of a resin strip having double ferrules.
    [0041] Figure 13 is an enlarged final view of another resin strip edge.
    [0042] Figures 14 and 14A are a final and perspective view of a resin strip edge having some resin overflow.
    [0043] Figures 15 and 15A are end and perspective views of a resin strip edge with a ferrule formed in a partially filled channel.
    [0044] Figures 16A and 16B are top and end views, respectively, of a first sample product.
    [0045] Figures 17A and 17B are top and end views, respectively, of a second sample product.
    [0046] Figure 18A is a perspective view of a diaper flap.
    [0047] Figure 18B is an enlarged view of area 18B in figure 18A.
    [0048] Figure 19 is a partial cross-sectional view of a molding space between a mold roll and a keyed injection head.
    [0049] Figure 20 illustrates another method and apparatus for the manufacture of a laminated touch fastener.
    [0050] Figure 21 shows a portion of an edge of a resin streak, in top view, with a sinusoidal profile.
    [0051] Same reference symbols in the various drawings indicate the same elements. DETAILED DESCRIPTION
    [0052] Referring first to figures 1 to 3, the touch fastener 100a includes a flexible substrate 102 and a plurality of defined structures 104. The structures 104 (such as molded fastener elements) extend from a layer of solidified base 106 of flowable resin (e.g., polypropylene, polyethylene or any other suitable resin material) supported by the substrate surface in a first region 108 of the substrate. A dividing line 110 represents a boundary between the first region 108 and a second adjacent region 112. In this example, substrate 102 is a fibrous nonwoven mat of a particular porosity that varies locally across the substrate surface. The substrate 102 can be, for example, what is known in the nonwoven industry as a loose fiber nonwoven, a needle punctured nonwoven, a spinning mat, such as a non-stitch mat, a mat wired / fused / wired (SMS), etc. Alternatively, substrate 102 can be a textile product, such as a knitted or woven product. In addition to porosity, other surface characteristics may also vary across the surface of the substrate 102, such as the local height of the surface. These substrate surfaces can have a topography that ripples across the surface, and the layer edge can traverse ripples on the surface. Some substrates, for example, are etched to form a desired surface topography.
    [0053] As described above, structures 104 extend from base layer 106. In this example, base layer 106 has a relatively straight edge 16 that has little or no chamfer. Edge 116 is arranged on the substrate surface in the first region 108 and adjacent to an exposed portion of the first region, as discussed in greater detail below. As shown, structures 104 are formed as J-hooks defining a twisted part to catch fibers of loop material. Structures 104, however, can be formed having other suitable shapes or sizes. With reference specifically to figure 3, the structures 104 are positioned in a standardized configuration in the base layer 106, which can be in the form of spaced parallel streaks extending along the substrate 102. Only one strip is shown in these figures. In some instances, the parallel lanes are approximately 15 millimeters wide, run along the length of the substrate 102 and are positioned approximately 15 millimeters from the outer edges of the substrate. These configurations and arrangements can be specifically advantageous in certain implementations (for example, for the formation of precursor materials for the manufacture of diaper flaps - see figure 18A). However, as discussed below, other suitable configurations or arrangements of base layers 106 and / or structures 104 are also envisioned (see figure 4, for example).
    [0054] The edges 116 of each strip of base layer 106 characterize an elevated ferrule 120 in which the thickness of the base layer is greater than in a region between the ferrule and the arrangement of structures 104. With thickness we mean the measurement of the base layer in the direction perpendicular to the substrate plane, as measured from a reference data corresponding essentially to the upper surface of the substrate. In the examples shown and discussed below, the base layer between the rim ferrules 120 and surrounding the structures is generally of a constant nominal thickness, from which the structures 104 can be considered discrete, local extensions formed from the same resin as the layer base. In this example, the ferrules 120 delimit the edges of each base layer strip 106, an outer edge of the ferrule being coextensive with and forming the distal edge of the base layer strip. In this case, the ferrules 120 are of generally constant width, as measured through the strip, have a relatively flat upper surface that is lower than the lockable heads of the fasteners 104, and are wider than an individual fastener.
    [0055] Referring then to Figures 4 and 5, the substrate regions covered by the resin base layer need not be straight strips. In this example, the base layer 106 is in the form of oval patches, each having an elevated ferrule 120 defining its perimeter. Structures 104a are in the form of discrete molded resin rods, rising vertically from the base layer. From these rods, fastening elements can later be formed by deformation of the distal ends of each rod to form a hanging head or plug (not shown in these views). The rods do not need to be arranged in straight rows or columns, but they can be arranged in other patterns, preferably with a spacing that allows separate insertable heads to be formed. The exposed substrate surface 102 surrounds each oval patch, so that each patch can be considered an island of resin covering and permanently laminated to the substrate surface. As shown in figures 2 and 5, the resin base layer preferably only penetrates the substrate to a limited depth, so that an opposite side of the substrate remains free of the resin of the base layer. The opposite side of the substrate can characterize loops or other fibers that can be joined by the structures of the base layers, when the touch fastener is wrapped around an object.
    [0056] With reference to figure 6, the ferrule 120 has a temperature, t1, which is greater than a nominal base layer thickness t0, as measured between the ferrule and the nearest functional structure 104a. Preferably, the thickness t1 in the ferrule is between about two and four times the thickness of the nominal base layer t0, or any thickness of the base layer between the frame arrangement 104a and the ferrule. In this example, the thickness difference (t1-t0) is around 0.0065 inches (0.16 mm), and the 'W' width of the ferrule is around 0.036 inches (0.91 mm). The inner edge of the ferrule is spaced from the surface closest to the nearest stem 104a by an ‘X’ distance of around 0.12 inches (0.3 mm). Due to the fact that the resin pressures required to properly mold the rods 104a (or the fastening elements 104 of figure 3), a separation distance 'X' is preferably at least 0.2 mm, and, for many applications, is in the range of 0.2 to 0.4 mm. In some cases, the rods 104a or the fastening elements are molded with stiffening ribs facing the edge ferrule 120, in which case the spacing distance 'X' is measured from the nearest stiffening rib surface. The ferrule 120 has an aspect ratio, defined as the ratio of the width W to the difference in thickness (t1-t0), which is preferably in the range of 2 to 5. Other ferrule configurations are described below.
    [0057] Referring below to Figure 7, a method of manufacturing a touch fastener 100a features continuous molding of the base layers and associated structures on a rotating mold roll 130, against which a resin is extruded under pressure by an extrusion nozzle 132 shaped to define a narrow space 134 between the nozzle and the mold roll. The basic configuration of such an apparatus is taught in U.S. Patent No. 5,669,120. In this space 134, the resin is extruded under pressure, and pressure forces the resin into discrete mold cavities 136 defined on the surface of the mold roll. In this example, the cavities 136 are shaped to form fastener elements 104 having hanging heads. In some other examples, only stems are formed. In any case, the resin remaining on the surface of the mold roll 130 forms the base layer 106 of resin, which is then laminated under pressure, in a pass between the mold roll 130 and a pressure roller turning in reverse 138, while the base layer is still carried on the mold roll and is sufficiently fused to partially embed in the substrate surface 102, without the use of added adhesives. Following lamination, the finished touch fastener 100a is removed from the mold roll and rolled up for later use.
    [0058] As shown in figure 8, the resin is applied to the mold roll in discrete strips, so that the base layer 106 is formed in spaced strips or bands on the substrate 102, leaving intermediate bands of the substrate surface free of the resin. . The circumferential grooves defined on the surface of the mold roll mold ferrules 120 at the edges of each strip. With reference also to figure 9, a resin is extruded on the mold roll surface in discrete streams by the extruder, such as through discrete die holes 140 spaced along the geometric axis of the laminated touch fastener. The face of the extruder defines an associated channel 142 that extends from each orifice 140 to the edge downstream of the face of the extruder. The side walls defining the channel help to restrict the laterally extruded resin, as the pressure in the extrusion space forces the resin into the cavities and the mold roll channels.
    [0059] Referring next to Figure 10, another method of manufacturing the touch fastener features the extrusion of a molten resin directly into a pass between the mold roll 130 and a smoothly running roll 138 around the which the substrate 102 is pulled, so that the substrate and the resin enter the pass together, and a pass pressure forces the resin into the mold roll cavities and channels, while directly laminating the resin base layer to the substrate, with a part of the resin penetrating interstices in the substrate surface to permanently attach the resin. In this example, extruder 144 is positioned to be aligned with the pass, and features a matrix hole with a rough edge that forms multiple spaced strips of resin that each form a continuous curtain in the pass, so that the resin contacts the substrate surface immediately before it is subjected to high pass pressure. In another arrangement (not shown), the extruder extrudes directly onto the substrate surface (for example, by extruding downward onto the surface) upstream of the molding pass. In any arrangement, the substrate and the moldable resin enter the pass together, and the same pressure that forces the resin into the mold cavities also forces the resin into the substrate. After traveling around the mold roll, the formed structures (for example, fasteners) are pulled out of their respective cavities and the finished touch fastener product is divided and / or rolled up for later use. In some embodiments, the mold roll cavities form straight, unhanged rods that are later deformed to form interlocking structures, such as by passing the molded rods under or against a heated roll or plate (not shown).
    [0060] As shown in figure 11, the mold roll 130 (employed in the method illustrated in figure 10 or figure 7) is constructed as an axially compressed pile of flat circular plates or rings. The mold rings 150, which have a shaped profile circumference for the definition of the longitudinal profiles of the structures 104 (for example, the J hooks, stems or palm hooks) to be molded, are interspersed between spacer rings 152 which have a continuous circular outer surface of constant diameter matching the diameter of the mold rings between the cavities. Each mold ring forms a corresponding longitudinal row of structures, and the thickness of the spacer rings defines the distance between the rows. As shown, some spacer rings 152 may be thicker than others, to produce the appropriate row spacing. A ferrule ring 154 of reduced diameter, compared to the spacer rings 152, is positioned to form the ferrule 120 at the edge of the base layer strip, and defines the base of the channel 155 in which the ferrule is formed. For the formation of a preferred aspect ratio ferrule, the ferrule channel has a depth, measured radially from the outer surface of the mold roll adjacent to the channel, which is between about 20 and 35 percent of the channel width. , measured along the geometric axis of rotation of the mold roll. A relatively thick spacer ring (or a stack of thinner spacer rings) is positioned between the ferrule ring 154 and the nearest mold ring 150, of a thickness selected to form the region between the ferrule and the arrangement of molded structures. . For some applications, this spacer ring is selected to be of a thickness such that the mold roll cavities closest to the ferrule forming channel are spaced from an edge close to the channel by a distance less than 0.8 times a width of the channel, measured along the geometric axis of rotation of the mold roll. Or to put it another way, the channel width in some cases is more than 1.2 times the distance from the channel to the nearest mold roll cavities. Some separation of the channel from the cavities is necessary to maintain sufficient pressure in the adjacent cavities for proper projection formation. We found, for example, that when molding typically dense arrangements of small polypropylene fasteners suitable for disposable diapers and the like, where the fasteners are only about 0.015 inches (0.4 mm) high, a distance of at least 0.008 inches (0.2 mm) was sufficient to fill the nearest mold cavities.
    [0061] This set of rings, including mold rings and spacers, interleaved between two ferrule rings, forms a ring set for forming a molded strip along the substrate, and is axially aligned with a flow of resin from the extruder. Each ring set is spaced from other ring sets by a relatively thick cylindrical ring 156 or set of rings. The ring 156 may be slightly larger in diameter than the nominal diameter of the mold ring, to provide a higher compression of the substrate and to prevent a flow of lateral resin beyond the ferrule channel.
    [0062] For molding structures of an appropriate size for fitting loops into a touch fastener, for example, mold rings 150 are relatively thin. In one example, each mold ring 150 of a mold roll of nominally 10 inch (25 cm) diameter has a thickness of only about 0.004 to 0.008 inch (from 0.10 to 0.20 mm). Filling these narrow cavities with resin with properties suitable for forming strong fastener hooks at commercial molding speeds requires significant pass pressures that act in all directions. When the entire length of the pass is used for molding, such as when covering an entire substrate surface with fastening elements, molding inconsistencies caused by variations in pass pressure near the edges of the substrate can be removed by stopping the edges of the substrate. substrate after molding. Away from the edges, the resin is generally restricted by the adjacent resin to flow upward into the cavities, and downward to the substrate. The shear effects caused by the rotation of the rollers can cause some longitudinal displacement, but far from the resin edges there is a relatively small lateral resin flow. When forming narrow strips of molded base layer under these high pressures, there is some lateral widening of the resin strip in the pass. The amount of enlargement tends to vary, due to variations in the substrate surface, local pressure fluctuations, etc. This can result in a visually unattractive lack of straightness at the edge of the molded strip.
    [0063] By providing a forming channel on the mold roll, positioned to match the edge of the molded strip, we have found that we can accommodate part of that pressure fluctuation, and improve the straightness of the strip edge as molded. In some sense, it is believed that the ferrule-forming channel acts as a type of lateral resin accumulator, whereby the pass pressure drops more precipitously during a pass impression than in cases where no channel such as this is provided. This can improve the straightness of the molded edge, regardless of whether the ferrule channel is completely filled, and even if some small amount of resin extends in front of the ferrule channel.
    [0064] Figures 12 to 15A illustrate several examples of strip edge configurations with edge grinding ferrule formations. In the example of figure 12, the strip edge was shaped to have a pair of ferrules 120, separated by a relatively thinner resin region. Each rib 120 was shaped to be 0.036 inches (0.9 mm) wide, and they were separated by a spacing of 0.008 inches (0.2 mm). In some cases, two ferrules can facilitate a smooth transition from free substrate to hook strip, to make the resin edge softer or provide the perception of softness. A resin extending to the external rib channel can be more readily detected during manufacture, allowing for better quality control and a finer process adjustment. Similarly, the strip edge shown in figure 13 features two spaced ferrules 120a, but with radius top edges for a softer feel. Alternatively, the upper edges can be chamfered. The inner ferrule is also shown to be narrower than the outer ferrule, to show that the ferrules do not have to be of equal thickness. In some cases, the ferrule closest to the fastening elements is wider than the external ferrule. Similarly, the ferrules need not be of equal height, but for most applications, the ferrules are preferably shorter than the functional fastener element 104 structures. The strip edge shown in figures 14 and 14A characterizes some overflow lateral 160 in addition to ferrule 120. Although the overflow has some visual lateral fluctuation (as shown in figure 14A), the general straightness of the resin rim is improved, compared to a similar strip formed without ferrule 120. Figures 15 and 15A show a strip edge formed on a mold roll with the same ferrule channel as the one formed with the ferrule shown in figure 14, but which was not completely filled with resin during the molding step. As a result, the thickness of the ferrule 120b varies across its width, and the ferrule has a free formed upper surface. The resin edge produced in this example has some visible fluctuation along its length, but again straighter than it would be produced without the forming ferrule 120b.
    [0065] The photographs in figure 16A and figure 16B show enlarged views of a strip edge molded to have a ferrule 120, as discussed above. In this example, small amounts of resin overflow 160 beyond the far edge of the ferrule are visible. Also shown in this example are reinforcement ribs 162 formed on the side of each fastener 104, facing rib 120. This particular resin strip was formed by polypropylene on a non-woven SMS substrate with a base weight of 60 grams per square meter. The molded palm hooks were 0.015 inches (0.38 mm) high and 0.006 inches (0.15 mm) thick. In an attempt to form this product with only a 0.3 mm thick spacer ring between the last row of fastening elements and the rib, the pressure reduction through the rib prevented the filling of the closest row of fastening elements completely.
    [0066] In the example shown in figures 17A and 17B, an internal rib channel essentially filled during a molding of the pass, forming the internal rib 120, while an external rib channel only partially filled, forming the external ferrule 120b. As can be seen in figure 17A, the outer rib 120b forms the longitudinal edge of the resin strip and has some width fluctuation. The pressure-reducing effect of the rib channels is also evident from the change in the thickness of the substrate seen in figure 17B. In areas of higher pass pressure, on the left side of the photograph, the resin has impregnated the substrate more deeply and the substrate is more crushed than under the edge ribs. This example was also formed with polypropylene resin and 60 g / m2 of non-woven SMS material.
    [0067] The cross-sectional size of the ferrule channel required to improve edge straightness will vary from application to application. It is believed that the higher the substrate porosity, the better the volume of ferrule channel that will be required, for example. Similar to higher viscosity resins, or for thinner substrates, less volume of ferrule channel may be required.
    [0068] Referring below to Figure 18A, a diaper 600 including a diaper chassis 602 (for clarity, the diaper chassis is not shown in detail in or in its entirety) and a diaper flap 604 extending from of the chassis and featuring a streak of loopable frame. More specifically, diaper flap 604 includes a substrate 606 (such as a stretchable non-woven material) having a base layer of resinous material 608 laminated on its surface. The interlocking loop structures (e.g., plugged rods or hooks) extend from the base layer 608. Diaper flap 604 can be made according to any method or system described above. As shown in the enlarged view of figure 18B, the variation in the edge 160 is significantly less than it would have been had the ferrule 120 not been formed (indicated for purposes of illustration as the dashed line 612).
    [0069] Another method of improving resin edge straightness in forming touch fastener regions on a substrate, particularly a substrate with a variable surface characteristic, is taught in pending US Patent Application 13 / 236,415, the content of which is incorporated here as a reference. The methods taught in that application are not incompatible with the methods taught above, and can be used in combination.
    [0070] The edge channel concepts discussed above can be combined with other molding apparatus features and methods, to obtain the desired edge properties. For example, with reference thereafter to figure 19, the method and apparatus of figure 7 can be modified to include a switch from the nozzle surface 132 to the mold roll 130. In this example, the nozzle surface 132 features ribs 700 received in grooves 702 extending around the mold roll immediately outside the channels 155 in which the ferrules are formed. In this case, the internal side walls of ribs 700 form the outer sides of channels 155, as flow barriers that form the edges of the molded resin streak. Slots 702 can be formed by stacking rings of desired diameters and thicknesses, as discussed above with respect to figure 11, or the outer diameters of different mold plates, if discussed above with respect to figure 11, or the outer diameters of plates thick mold can be rotated to create the desired grooves 702 and channels 155 the width of a single mold plate. Referring also to figure 20, any fillet that forms in the mold roll grooves 702 can be trimmed while the resin is still cooling the mold roll, by a set of blades 706 that extend into the grooves and scrape through the least against the inner walls of the grooves. The removed fillet 708 is then guided away from the mold roll and recycled. The trimmed streaks of resin can then pass over a radiant heater 710, to soften the exposed rear surfaces, of the base layer 106, just before the introduction of substrate 102, which is laminated under a pressure pass to the softened resin surfaces. or slightly fused, while still carried on the mold roll 130. In this way, very precise fastener streak edges can be formed in the laminate.
    [0071] The switching concept described above with respect to figure 19 can also be used to use a key in a mold roll and a pressure roller, as a variation of the method and apparatus featured in figure 10. In an example like this , trimming can take place immediately downstream of the molding pass, before introducing the substrate into an additional pass against the mold roll. Furthermore, the concept of using a key can be employed, with an extrusion nozzle or a molding pass, separate from the concepts of edge rib formation discussed above. In other words, a variation of the mold space arrangement shown in figure 19 does not include any rib forming channels 155, but otherwise appears as shown.
    [0072] Although the examples of longitudinal edge ribs discussed above have generally been illustrated as being linear, with straight side walls, in some situations it may be desirable to form a longitudinal edge rib that follows a desired non-linear path. For example, figure 21 illustrates an edge rib 120c formed in a molding channel that follows a sinusoidal or otherwise serpentine path, so that the distance between the rib and the molded fastener elements ripples along the length of the laminate. This undulation can induce a longitudinal flow locally of the resin under a molding pressure, in those regions where the rib is more distant from the fastener elements. A wavy rib like this can be considered preferable over a perfectly straight edge, for example, in some personal care products. The formation of the rib helps to achieve a desired edge pattern like this from a generally constant extrusion of resin.
    [0073] Although several examples have been described for purposes of illustration, the foregoing description is not intended to limit the scope of the invention, which is defined by the scope of the appended claims. There are and will be other examples and changes in the scope of the following claims.
    权利要求:
    Claims (15)
    [0001]
    1. Method of making a laminated touch fastener (100), the method comprising the steps of: introducing a flowable resin into a limited region of an outer surface of a rotating mold roll (130) that defines an arrangement of cavities (136) extending inwardly from an external surface of the mold roll; applying pressure to the resin to fill the cavities with resin and forming a layer (106) of the applied resin by interconnecting projections (104) molded into the cavities; and laminating the resin layer to a flexible substrate (102), while the resin layer is carried on the mold roll, the substrate being wider than the resin layer, thereby forming a laterally bounded layer of resin a from which the molded projections extend, the bounded layer laminated to the substrate and having at least one layer edge adjacent to an exposed region of the substrate (102), the layer having a selvedge region devoid of the molded projections (104) and defined between the projections and the layer edge; characterized by the fact that the mold roll defines a continuous channel (155) that extends around the mold roll and positioned so that the resin at least partially fills the channel, thereby forming a raised portion (120) in the channel of the selvedge region in which the resin layer is thicker than at a point between the arrangement and the raised portion, where the edge of the layer is formed within the channel (155)
    [0002]
    2. Method according to claim 1, characterized in that the pressure is applied in a pass between the mold roller (130) and a pressure roller turning in reverse (138).
    [0003]
    Method according to claim 1, characterized in that the layer edge is formed against an axially distal wall that defines the channel.
    [0004]
    Method according to any one of the preceding claims, characterized in that the resin fills the channel (155), so that the resin layer is shaped to have a shape of the channel.
    [0005]
    5. Method according to any one of the preceding claims, characterized in that the mold roll cavities closest to the channel are spaced from an edge close to the channel by a distance less than 0.8 times a width of the channel, measured along a geometric axis of rotation of the mold roll.
    [0006]
    Method according to any one of the preceding claims, characterized in that the substrate (102) is porous and the flowable resin is pressed into the pores of the substrate, while the resin is carried on the mold roll (130).
    [0007]
    Method according to claim 6, characterized in that the substrate surface is of a topography that ripples across the surface, the layer edge crossing the surface ripples.
    [0008]
    Method according to any one of claims 1 to 7, characterized in that the resin layer is of a thickness in the raised portion that is between about two and four times the thickness of the layer at a point between the arrangement and the elevated portion.
    [0009]
    Method according to any one of the preceding claims, characterized in that the channel (155) has a depth that is less than a depth of the cavities (136).
    [0010]
    Method according to any one of the preceding claims, characterized in that the channel (155) follows a serpentine path around the mold roll.
    [0011]
    11. Method according to any one of the preceding claims, characterized in that the mold roller (130) defines grooves (702) immediately outside the channels (155) and forming an external side of each channel, and in which the ribs (700) are arranged in the grooves during the application of pressure and prevent lateral flow of the flowable resin.
    [0012]
    12. Touch fastener product, comprising: a flexible sheet-shaped substrate (102) having a wide surface; a layer of resin (106) laminated directly to the wide surface, the layer of resin covering only a portion of the wide surface and defining a layer edge adjacent to an exposed region of the wide surface; and an array of discrete fastener projections (104) extending from the resin layer; characterized by the fact that; the resin layer is thicker at the layer edge than at a point between the arrangement and the layer edge; wherein the layer edge comprises a rib (120), and where the layer defines a selvedge area extending from the fastener projection arrangement to the rib (120), the selvedge area being of a lesser thickness than a thickness of the resin layer on the rib.
    [0013]
    13. Product according to claim 12, characterized in that the rib (120) is shorter than the fastener elements (104).
    [0014]
    Product according to claim 12 or 13, characterized in that the substrate (102) is longitudinally continuous and the resin layer (106) forms a discrete band of resin running along a length of the substrate.
    [0015]
    Product according to any one of claims 12 to 14, characterized in that the resin layer (106) covers only a delimited area of the wide substrate surface, surrounded by the exposed region of the wide surface, the layer edge comprising a rib (120) extending around a periphery of the resin layer.
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    同族专利:
    公开号 | 公开日
    US10531711B2|2020-01-14|
    CN104320990B|2018-09-28|
    US9399333B2|2016-07-26|
    CN104320990A|2015-01-28|
    WO2013156368A1|2013-10-24|
    US20160309855A1|2016-10-27|
    EP2838396B1|2017-06-07|
    US20130280474A1|2013-10-24|
    EP2838396A1|2015-02-25|
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    法律状态:
    2018-04-03| B25A| Requested transfer of rights approved|Owner name: VELCRO BVBA (BE) |
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-12-03| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-11-24| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-02-09| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 10/04/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    2021-06-08| B25A| Requested transfer of rights approved|Owner name: VELCRO IP HOLDINGS LLC (US) |
    优先权:
    申请号 | 申请日 | 专利标题
    US201261635070P| true| 2012-04-18|2012-04-18|
    US61/635,070|2012-04-18|
    PCT/EP2013/057494|WO2013156368A1|2012-04-18|2013-04-10|Forming laminated touch fasteners|
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